U.S. patent application number 16/139476 was filed with the patent office on 2019-03-28 for elastomeric, electrical insulator with one or more additional protective properties.
The applicant listed for this patent is IDEAL Industries, Inc.. Invention is credited to David G. Kotowski, Andrew Meyer, Sam Peterson, Joseph Saganowich, Douglas A. Sanford, Michael Weiby, Alan E. Zantout.
Application Number | 20190097350 16/139476 |
Document ID | / |
Family ID | 65809373 |
Filed Date | 2019-03-28 |
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United States Patent
Application |
20190097350 |
Kind Code |
A1 |
Sanford; Douglas A. ; et
al. |
March 28, 2019 |
ELASTOMERIC, ELECTRICAL INSULATOR WITH ONE OR MORE ADDITIONAL
PROTECTIVE PROPERTIES
Abstract
An apparatus for insulating electrical terminals of an
electrical connection device, such as a light switch or outlet. In
an example, the electrical connection device has a first outer
circumference, while the apparatus has a second outer circumference
that is less than the first outer circumference. The apparatus is
to be fitted around the electrical connection device and be
maintained thereon by an elastic force of the apparatus.
Inventors: |
Sanford; Douglas A.;
(Naperville, IL) ; Kotowski; David G.; (Geneva,
IL) ; Saganowich; Joseph; (Cary, NC) ;
Zantout; Alan E.; (Sycamore, IL) ; Weiby;
Michael; (Bartlett, IL) ; Peterson; Sam;
(Sycamore, IL) ; Meyer; Andrew; (Yorkville,
IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
IDEAL Industries, Inc. |
Sycamore |
IL |
US |
|
|
Family ID: |
65809373 |
Appl. No.: |
16/139476 |
Filed: |
September 24, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62563293 |
Sep 26, 2017 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01R 13/5213
20130101 |
International
Class: |
H01R 13/52 20060101
H01R013/52 |
Claims
1. An article for insulating an electrical connection device, the
article comprising: a substantially elastic insulator manufactured
of an electrically insulating material and a flame retarding
material, the insulator having a thickness that insulates a user
from an electrical current associated with the electrical
connection device, a width dimensioned to cover at least a portion
of the electrical connection device at which inadvertent contact
with the electrical current is possible, and a length and an inside
opening width dimensioned to encircle the at least a portion of the
electrical connection device and provide an elastic force upon the
electrical connection device to maintain the insulator in position
upon, and to prevent breakage and springing from, the electrical
connection device.
2. The article as recited in claim 1, wherein the substantially
elastic insulator is in the form of a band.
3. The article as recited in claim 2, wherein the elastic insulator
include complimentary locking elements for forming the band.
4. The article as recited in claim 1, wherein the elastic insulator
is in the form of a cup.
5. The article as recited in claim 1, wherein the electrical
connection device comprises a splice connector.
6. The article as recited in claim 1, wherein the electrical
connector comprises an outlet box.
7. The article as recited in claim 1, wherein the insulator
comprises a thermoplastic elastomer (TPE) material.
8. The article as recited in claim 1, wherein the insulator
comprises a nitrile material.
9. The article as recited in claim 1, wherein the insulator
comprises an ethylene propylene diene monomer (EPDM) rubber
material.
10. The article as recited in claim 1, wherein the insulator
comprises a silicone material.
11. The article as recited in claim 1, wherein the insulator is
continuous and has a substantially circular shape when the
insulator is in a resting state.
12. The article as recited in claim 1, wherein the insulator is
continuous and has a substantially rectangular shape when the
insulator band is in a resting state.
13. The article as recited in claim 1, wherein the insulator is
formed with a pull tab and wherein the pull tab extends outwardly
in a direction away from the inside opening of the insulator.
14. The article as recited in claim 13, wherein the pull tab has an
opening formed therethrough.
15. The article as recited in claim 1, wherein the insulator
includes a portion that provides a spacing between the insulator
and the electrical connection device when the insulator band is
maintained in position upon the electrical connection device.
16. The article as recited in claim 1, wherein the insulator
comprises an ultraviolet (UV) inhibiting material.
17. The article as recited in claim 1, wherein the insulator
comprises an oxidation resisting material.
18. The article as recited in claim 1, wherein the insulator
comprises a water absorption resisting material.
19. An article for insulating an electrical connection, the article
comprising: a substantially elastic insulator manufactured of an
electrically insulating material and an ultraviolet (UV) inhibiting
material, the insulator having a thickness that insulates a user
from an electrical current associated with the electrical
connection device, a width dimensioned to cover at least a portion
of the electrical connection device at which inadvertent contact
with the electrical current is possible, and a length and an inside
opening width dimensioned to encircle the at least a portion of the
electrical connection device and provide an elastic force upon the
electrical connection device to maintain the insulator in position
upon, and to prevent breakage and springing from, the electrical
connection device.
20. The article as recited in claim 19, wherein the insulator
comprises a thermoplastic elastomer (TPE) material.
21. The article as recited in claim 19, wherein the insulator
comprises a nitrile material.
22. The article as recited in claim 19, wherein the insulator
comprises an ethylene propylene diene monomer (EPDM) rubber
material.
23. The article as recited in claim 19, wherein the insulator
comprises a silicone material.
24. The article as recited in claim 19, wherein the insulator is
formed with a pull tab and wherein the pull tab extends outwardly
in a direction away from the inside opening of the insulator.
25. The article as recited in claim 19, wherein the pull tab has an
opening formed therethrough.
Description
RELATED APPLICATION INFORMATION
[0001] This application claims the benefit of U.S. Application No.
62/563,293, filed on Sep. 26, 2017, the disclosure of which is
incorporated herein by reference in its entirety.
FIELD OF THE DISCLOSURE
[0002] The present description relates generally to elastomeric,
electrical insulators.
BACKGROUND OF RELATED ART
[0003] Electrical connection devices, such as light switches,
outlets (collectively "outlet boxes"), splice connectors, and the
like, often have an electrical connection component, such as a
screw terminal, a coil spring, etc., to which one or more
electrical wires are to be connected. Electricians sometimes choose
to wrap such devices with a heat-shrink material, electrical tape,
and/or a band to prevent unwanted contact with the wires and/or the
electrical connection components as described, by way of example,
in U.S. Pat. Nos. 6,478,606, 6,664,477, and 8,803,007.
SUMMARY
[0004] The following generally describes insulators for use with
electrical connection devices as well as methods for making the
same. The described insulators are manufactured to be resilient,
electrically insulating, and to have additional protective
properties, e.g., to be flame retarding and/or UV inhibiting. In a
described, non-limiting example, an insulator is in the form of a
band and has a thickness that insulates a user from an electrical
current, a width dimensioned to cover the electrical connection
component(s) associated with the electrical connection device, and
a length and an inside opening width dimensioned to provide an
elastic force upon the electrical connection device to maintain the
insulator in position upon, and to prevent breakage and springing
from, the electrical connection device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a perspective view of an example insulator in the
form of an elastomeric insulation band.
[0006] FIG. 2 is a perspective view of an example insulator in the
form of an elastomeric insulation band with a pull tab.
[0007] FIG. 3 is a perspective view of an example insulator in the
form of an elastomeric insulation band.
[0008] FIG. 4 is a perspective view of an example insulator in the
form of an elastomeric insulation band with a pull tab.
[0009] FIG. 5 is a diagram illustrating an example use of an
insulator.
[0010] FIG. 6 is a perspective view of an example insulator in the
form of a strip that is formable into a band.
[0011] FIG. 7 is a perspective view of the insulator of FIG. 6
disposed on an electrical connection device in the form of an
outlet.
[0012] FIG. 8 is a side view of an example insulator in the form of
a strip that is formable into a band.
[0013] FIG. 9 is perspective view of an example insulator in the
form of a cup disposed on an electrical connection device in the
form of an outlet.
[0014] FIG. 10 is perspective view of an example insulator in the
form of a band disposed on an electrical connection device in the
form of a splice connector.
[0015] FIG. 11 is perspective view of an example insulator in the
form of a cup disposed on an electrical connection device in the
form of a splice connector.
DETAILED DESCRIPTION
[0016] The following description of example methods and apparatuses
is not intended to limit the scope of the subject insulators to the
precise form or forms detailed herein. Instead the following
description is intended to be illustrative so that others may
follow its teachings.
[0017] The present application discloses example insulators for use
with electrical connection devices. The insulators described herein
are elastomeric, such that they can be stretched to fit around the
electrical connection device. The insulators are then held in place
by the contracting force of the elastomer, without the need for
additional adhesives. Accordingly, the insulation bands can be
easily installed on or removed from electrical connection devices,
and may be reused on a further electrical connection device (e.g.,
using the same insulation band when replacing a light switch).
[0018] As one example, an insulator may be in the form of a band
and the band may be formed from an extruded elastomer. The
elastomer may be formed from one or more separate materials, each
contributing different properties to the insulator. For instance,
silicone may provide elasticity, insulation, and thermal
resistance, among other properties. One or more compounds (also
referred to herein as "fillers") may be added to the silicone to
enhance its properties, or provide new beneficial properties to the
resulting material. For example, in humid environments, it may be
preferred to have a material with low water absorption; one or more
fillers may be introduced to the silicone to enhance its water
resistance. Other fillers may be added to produce a material that
is flame retardant, ultra violet (UV) resistant, increase the
material's tensile strength, increase the dielectric strength of
the material, or increase the operating temperature range of the
material, among other properties.
[0019] In some examples, the insulator is coated with one or more
materials that enhance existing properties of the insulator and/or
provide additional properties to the insulator. For example, a
liquid material may be sprayed onto the insulator to enhance the
insulator's resistance to UV light, thereby extending the life of
the insulator. Other coatings may provide other properties
described hereinafter.
[0020] In some instances, the compound or combination of compounds
used to form an insulator are selected to comply with local
regulations, standards requirements, and/or environmental
regulations. Additionally, a given insulator may be designed to be
fitted with an electrical connection of a particular shape and
size. Such an insulator will generally have dimensions that are
smaller than the electrical connection device, so that the
insulator may be stretched around the exterior surface of the
electrical connection device and tightly held in place when
released (i.e., by the "elastic force" of the stretched material of
which the insulator is comprised).
[0021] Some insulators are extruded or otherwise manufactured to
form one or more features on the insulator e.g., to assist with the
installation and removal of the insulator from electrical
connection devices. For example, a pull tab may be provided on the
insulator, which can be gripped and pulled to stretch the insulator
for removal or installation purposes. An insulator may also be
extruded to introduce a feature to assist in removal or
installation purposes; for example, the insulator may be provided
with a rigid or semi-rigid portion, e.g., a portion that is not as
resilient as the remainder of the insulator, that will generally
maintain its shape and which is arranged to protrude outward even
when the insulator is released upon an electrical connection device
to thereby provide a gap between the insulator and the electrical
connection device within which an electrician can place a finger,
place additional material, such as a water resistant material, an
anti-oxidizing material, a fire retarding material, an electrically
insulating material, etc.
[0022] Although specific examples are described herein, it is to be
understood that any combination of materials and/or manufacturing
processes may be used to form the insulators hereinafter
described.
[0023] FIGS. 1-4 illustrate different insulators in the form of
elastomeric insulation bands. Although specific shapes and
configurations are shown, any insulator described herein is
intended to be capable of being stretched and/or contracted to
temporarily modify its shape and dimensions. For example, an
insulator may have a "rest" radius which can be modified by
subjecting the insulator to a force (e.g., an electrician
stretching an insulating band for placement around an electrical
connection device). It will be understood that FIGS. 1-4 show the
resting shape of the insulating, elastomeric bands.
[0024] FIG. 1 is a perspective view of an example elastomeric
insulation band 100. In this example, the elastomeric insulation
band 100 is a continuous circular ring. The elastomeric insulation
band 100 may be initially formed from a long tube of extruded
material, which is then cut at periodic lengths to produce the
elastomeric insulation band 100.
[0025] Some insulators, including elastomeric insulation band 100,
may be "continuous" in that there are no seams or joints within the
insulator. Such continuity may be achieved through extrusion or
injection molding, among other manufacturing techniques.
[0026] FIG. 2 is a perspective view of an example elastomeric
insulation band 200 with a pull tab 201. In this example, the
elastomeric insulation band 200 is initially formed as a flat
rectangular strip of material (e.g., synthetic rubber,
thermoplastic elastomer, etc.). Opposite ends of the strip are then
brought together and joined, via curing or adhesive, to form a
closed loop.
[0027] The pull tab 201 may serve as a handle for a user or
electrician to grip onto, to assist in the installation or removal
of the elastomeric insulation band 200. The pull tab 201 may
include other features thereon and/or therethrough, such as a
roughened texture to enhance grip or a hole extending through the
pull tab 201 for hanging the elastomeric insulation band 200 on a
ring (e.g., on an electrician's tool belt). In some instances, a
grommet or the like, preferably constructed from a non-conductive
material, can be placed into a hole formed through the pull tab 201
to provide further mechanical stability to the hole. It will also
be appreciated that insulation band may be molded with a pull
tab.
[0028] FIG. 3 is a perspective view of an example elastomeric
insulation band 300. In this example, the elastomeric insulation
band 300 is a continuous, generally rectangular shaped loop. The
elastomeric insulation band 300 may be initially formed from a long
extruded rectangular prism, which is cut into separate bands.
Alternatively, the elastomeric insulation band 300 may be formed
from injection molding, or curing of a synthetic rubber.
[0029] The elastomeric insulation band 300 may, in some instance,
be substantially rectangular with beveled or curved edges. The
shape of the elastomeric insulation band 300 is preferably
substantially similar to the shape provided by exterior walls of an
electrical connection device with which the elastomeric insulation
band 300 is to be used. As will be understood, the interior
dimensions of the elastomeric insulation band are intended to be
smaller than the exterior dimensions of the electrical connection
device with which the elastomeric band 300 is to be used to thereby
ensure that the elastomeric insulation band 300 will snuggly extend
around the electrical connection device when installed
thereupon.
[0030] FIG. 4 is a perspective view of an example elastomeric
insulation band 400 with a pull tab 401. In this example, the
elastomeric insulation band 400 may be initially formed as a flat,
elongated strip of material, which is fitted around or pressed into
a substantially rectangular mold. Opposite ends of the strip may
then be joined together to form a closed loop, with the joined
portion serving as the pull tab 401. A variety of manufacturing
techniques may be used to form the shape of the elastomeric
insulation band 400, without departing from the scope of the
present application. As before, the pull tab 401, which in this
example is located at a corner area of the insulation band 400, may
be provided with a hole, grommet, or the like for the purposes
discussed above.
[0031] FIG. 5 is a diagram 500 illustrating a use of an elastomeric
insulation band 503. In this example, it will be understood that
insulation band 503 may be any insulator disclosed within this
document. An example AC wall outlet includes a receptacle 501, an
outlet 502, and a wall plate 503. The outlet 502 includes thereon
screw terminals 504, which mechanically secure wiring for AC power
to the outlet 502. When assembled, the outlet 502 is fitted
partially within the receptacle 501; then, the wall plate 503 is
secured to the front of the outlet 502.
[0032] As shown in FIG. 5, an example use of the elastomeric
insulation band 503 involves fitting the band around the exterior
side wall surfaces of the rear portion of the outlet 502, covering
the screw terminals 504. In this manner, the risk of shorting the
screw terminals when handling the outlet 502 is significantly
reduced.
[0033] FIGS. 6 and 7 illustrate an insulator 600 in the exemplary
form of a strip of resilient material that is provided with a
locking feature that is comprised of cooperating locking elements
602 and 604 that, when engaged, function to turn the strip of
resilient material into a band for use as described above. As will
be appreciated, the locking elements 602 and 604 can be engaged to
form the insulator 600 into a band prior to the insulator 600 being
placed upon an electrical connection device, e.g., outlet 502.
Likewise, the locking elements 602 and 604 can be engaged to form
the insulator 600 into a band after the insulator 600 is stretched
around the surface of the electrical connection device that is to
be protected. To provide for some degree of adjustability, the
locking feature can be provided with plural elements 602 and/or
plural elements 604. While illustrated as a protrusion (having an
larger sized head portion) that is intended to be releasably
positioned within a one of plural apertures, it will be appreciated
that the locking feature can use hook and loop fastening elements,
e.g., "VELCRO," use an adhesive, use cable tie like fastening
elements, such as illustrated in FIG. 8 or as disclosed in U.S.
Pat. Nos. 4,532,679 and 9,682,806, and the like without
limitation.
[0034] While the foregoing examples provide an insulator in the
form of a band, in a further example, the insulator may have a cap
or cup-like shape as illustrated in FIG. 9. In this example, the
insulator 900 is intended to cover not only the sides of the
electrical connection device, e.g., outlet 502, but to also cover
the back side of the electrical connector device. While illustrated
as being formed as a single, integral component, it will be
appreciated that this form of the insulator 900 may be constructed
from multiple components that are mated together as discussed
above. In some instances, the insulator 900, for example the
portion intended to cover the back side of the electrical connector
device, may be provided with one or more openings and/or one or
more predefined areas that may be punctured or the like to form an
opening for use in directing a wire through the insulator 900
towards the electrical connection device.
[0035] In some instances, an insulator may be formed to provide one
or more dimples or the like for use in holding a desired material,
in particular, at a location over one or more electrical connection
components, such as screw terminals 504, of the electrical
connector device. Such dimples may be provided to the insulator by
being molded into the insulator, by being formed in the insulator
via use of heat or pressure, by using a material with a different
degree of elasticity as compared to surrounding areas of the
insulator, by varying the thickness of the material from which the
insulator is constructed, or the like. The dimples may be formed so
as to be visible when the insulator is "at rest," e.g., the dimples
would be seen to extend outwardly from the insulator, or may be
formed so as to become visible when material is positioned under
the dimple with the insulator otherwise being installed on the
electrical connector device. Thus, it will be appreciated that a
dimple area on an insulator may be a portion of the insulator that
differs from surrounding portions of the insulator by being more
rigid or more elastic relative thereto without limitation. When the
insulator is positioned upon an electrical connector device, the
dimple provides a means for a user to position one or more of a
water resistant material, an anti-oxidizing material, a fire
retarding material, an electrically insulating material, or other
material as desired for any given purpose, between the insulator
and an electrical connection components.
[0036] As further shown in FIGS. 10 and 11, the subject insulator
may also be sized and arranged to be snuggly fit over electrical
connection devices beyond the illustrated outlet 502. For example,
the insulator, which may be in the form of a band 1000 or in the
form of a cup 1100, may be sized and arranged to cover, in whole or
in part, a housing 10002 of a splice connector while providing an
elastic seal 1004 over the opening of the housing 1002 into which
wires are to be inserted. In preferred embodiments, the elastic
seal 1004 is also intended to be tightly held in place upon the
wires that are inserted into the splice connector when the
insulator is released thereupon. In some instances, the elastic
seal 1004 may be provided with one or more predefined areas that
may be punctured or the like to form an opening for use in
directing a wire through the insulator towards the opening of the
splice connector.
[0037] As noted previously, elastomeric insulators of the present
disclosure are to be formed from a material or combination of
materials (hereinafter "material") that possess one or more
desirable properties, including electrical properties, thermal
properties, mechanical properties, and/or resistance to
environmental conditions, among other properties. For example, a
material may have a particular amount of resistivity and/or
dielectric strength (e.g., per unit thickness) to meet a given
application. A material may also be adapted to withstand a range of
temperatures without significantly affecting its insulating
properties or longevity. The materials will have the tensile
strength to allow the insulator to tightly grip an electrical
connection device with which the insulator it to be used.
[0038] In some instances, a material may be resistant to
ultraviolet light degradation. Such a material may be preferred in
environments where the elastomeric insulation band is exposed to
sunlight. In further instances, the material may be provided with
chemicals to make the material glow in the dark, illuminate under
certain lighting conditions, etc.
[0039] The material may also be flame resistant or flame retardant,
which reduces the chance of the elastomeric insulator catching on
fire. As one example, a flame retardant additive is added to
synthetic rubber before or during the curing process, thereby
forming a flame resistant material.
[0040] Other materials may resist degradation from other
environmental conditions. Certain materials and/or additives may
reduce water absorption, which might be preferred in humid or wet
environments. A given material or additive may be oxidation
resistant as well.
[0041] In forming an elastomeric insulator, selecting the material
or combination of materials may depend on a variety of factors,
including the environmental conditions expected, the cost of
materials and manufacturing, municipal codes, and/or federal
regulations, among other factors. Compliance with some existing
standards--such as UL 224 (standard for safety extruded insulating
tubing), UL 510 (standard for polyvinyl chloride, polyethylene and
rubber insulating tape), and UL 94 (standard for tests for
flammability of plastic materials for part sin devices and
appliance)--may be considered. As technology advances, additional
standards may also be developed and considered when manufacturing a
given elastomeric insulator.
[0042] Some example materials which may be used in forming an
elastomeric insulator of the present disclosure include: ethylene
propylene (EPDM), polysiloxane (silicone), nitrile, polychloroprene
(e.g., Neoprene), styrene butadiene, fluorocarbon, hydrogenated
nitrile, isobutylene isoprene, fuorosilicone, urethane,
polyisoprene, synthetic polyisoprene, thermoplastic insulators
(TPEs), and/or other materials.
[0043] Each of these materials may have respective advantages and
disadvantages. For example, one material may have excellent tensile
strength, but naturally poor flame resistance. Others may have
great flame resistance and electrical insulation, but at a high
cost. Given the variety of potential applications for an
elastomeric insulator of the present disclosure, the material or
combination of materials used may depend on a desired property or
combination of properties.
[0044] In manufacturing the elastomeric insulator, a variety of
processes may be used, which may depend on the particular
material(s) used to form the insulator. For example, forming a band
from synthetic rubber may involve a combination of extruding
synthetic rubber into a long tube, placing those tubes on mandrels,
curing the rubber with heat, and slicing the cured rubber along the
width of the tube into smaller bands.
[0045] For other materials, such as TPEs, either extrusion or
injection molding may be used to form the insulator. For injection
molding, TPE is heated, melted, and injected into a molding machine
where it cools and solidifies in the shape of the mold. Unlike
synthetic rubbers, forming insulators from TPE does not involve a
curing stage, potentially reducing the manufacturing time and cost.
TPE injection molding may be preferred in implementations where an
elastomeric insulator has complex shapes or features, such as
protrusions or pull tabs.
[0046] Although certain example methods and apparatuses have been
described herein, the scope of coverage of this patent is not
limited thereto. On the contrary, this patent covers all methods,
apparatus, and articles of manufacture fairly falling within the
scope of the appended claims either literally or under the doctrine
of equivalents.
* * * * *